Roof frame bracket assembly

ABSTRACT

A roof frame includes a roof rail having a bottom, a bracket assembly, and a pillar. The bracket assembly includes a bracket inner and a bracket outer fixed to each other. The bracket inner and the bracket outer fixed to the bottom of the roof rail. The pillar includes a pillar inner fixed to the bracket inner and a pillar outer fixed to the bracket outer. The pillar inner and the pillar outer fixed to each other.

BACKGROUND

A vehicle a roof assembly may have a roof frame and one or more roofpanels supported by the roof frame. The one or more roof panels may bereleasably connected from the roof frame. When the one or more roofpanels are connected to the roof frame, the one or more roof panelscovers the roof frame of the vehicle, i.e., shields the roof frame fromthe environment. When the one or more roof panels are released from theroof frame, the roof frame is exposed to the environment, e.g., wind,water, debris, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is perspective view of a vehicle including a roof frame and anexterior panel covering the roof frame.

FIG. 1B is a magnified view of a portion of the vehicle with theexterior panel removed and the roof frame exposed to the environment

FIG. 2 is magnified view of a portion of the roof frame including a roofrail and a bracket assembly and a pillar fixed to the roof rail.

FIG. 3 is an exploded view of the bracket assembly and the pillar ofFIG. 2.

FIG. 4A is a perspective view of the bracket assembly including abracket outer fixed to a bracket inner.

FIG. 4B is an exploded view of the bracket assembly in FIG. 4A.

DETAILED DESCRIPTION

A roof frame includes a roof rail having a bottom. A bracket assemblyincludes a bracket inner and a bracket outer fixed to each other. Thebracket inner and the bracket outer are fixed to the bottom of the roofrail. A pillar includes a pillar inner fixed to the bracket inner as apillar outer fixed to the bracket outer. The pillar inner and the pillarouter are fixed to each other.

The bracket outer may include a surface extending in a vehiclefore-and-aft direction, the surface being fixed to the bottom of theroof rail.

The roof rail may include an inner side and an outer side spaced fromeach other in a cross-vehicle direction. The inner side and the outerside extending from the bottom in a direction transverse to thecross-vehicle direction.

The bracket inner may include a flange extending in the direction alongthe inner side of the roof rail. The flange may be fixed to the innerside of the roof rail.

The bracket inner may include wings spaced from each other in a vehiclefore-and-aft direction. The wings may be fixed to the bottom of the roofrail.

The bracket outer may include a surface extending in the vehiclefore-and-aft direction from one wing to the other wing. The surface andthe wings may extend in a plane along the bottom of the roof rail.

The bracket inner may include the flange elongated in the vehiclefore-and-aft direction, the surface includes an inner edge abutting theflange from one wing to the other wing.

The surface may include an outer edge spaced from the inner edge in across-vehicle direction. A seal may be sandwiched between the outer edgeof the surface and the bottom of the roof rail. The seal may extend fromone wing to the other wing.

The bracket assembly may include a seal sandwiched between the bracketinner and the bracket outer.

The bracket inner may include sealing surfaces spaced from each other ina vehicle fore-and-aft direction. Each sealing surface may include a topsurface extending in a cross-vehicle direction and a front surfaceextending in a direction transverse to the cross-vehicle direction.

The bracket outer may include an inner surface abutting the sealingsurfaces. The inner surface may extend along each sealing surface fromthe top surface to the front surface.

The seal may be disposed along each sealing surface from the top surfaceto the front surface.

Each sealing surface may include a transition surface extending from thetop surface to the front surface. The seal may be disposed along thetransition surface.

The pillar inner may include walls spaced from each other in a vehiclefore-and-aft direction and a back extending from one wall to the otherwall. The walls and the back may define a channel and the bracket innerdisposed in the channel.

The bracket inner may abut the walls and the back of the pillar inner.The bracket inner may be fixed to the pillar inner in the channel.

The pillar inner may include a weld flange extending from each wall awayfrom the channel in the vehicle fore-and-aft direction, and the pillarouter may include mounting flanges spaced from each other in the vehiclefore-and-aft direction. The mounting flanges of the pillar outer mayabut the weld flanges of the pillar inner, respectively.

A seal may be sandwiched between the mounting flanges of the pillarouter and the weld flanges of the pillar inner.

The pillar may include a body side panel encompassing the pillar outer.The mounting flanges of the pillar outer may be sandwiched between thebody side panel and the weld flanges of the pillar inner.

The pillar may include a body side panel encompassing the pillar outerand the bracket outer. The body side panel may be fixed to the pillarouter and the bracket outer.

The body side panel may be fixed to the pillar inner.

With reference to the Figures, wherein like numerals indicate like partsthroughout the several views, a vehicle 10 is generally shown. Thevehicle 10 includes a roof assembly 12 having a roof frame 14 and atleast one exterior panel 16 releasably connectable with the roof frame14. The at least one exterior panel 16 may be releasable from a coveredposition, shown in FIG. 1A, to an uncovered position. When the at leastone exterior panel 16 is in the uncovered position, the roof frame 14 isexposed to the environment, e.g., water, debris, etc., as shown in FIG.1B. The roof frame 14 is assembled to prevent intrusion, e.g., by water,debris, etc., into the roof frame 14 when the at least one exteriorpanel 16 is in the uncovered position, which may prevent or reducecorrosion of the roof frame 14 and other vehicle components, e.g.,rockers.

The roof frame 14 includes a roof rail 18, a bracket assembly 20, and apillar 22. The roof rail 18 includes a bottom 24. The bracket assembly20 includes a bracket inner 26 and a bracket outer 28 fixed to eachother. The bracket inner 26 and the bracket outer 28 are fixed to thebottom 24 of the roof rail 18. The pillar 22 includes a pillar inner 30fixed to the bracket inner 26 and a pillar outer 32 fixed to the bracketouter 28. The pillar inner 30 and the pillar outer 32 are fixed to eachother. The bracket assembly 20 is designed to conform to the shape ofthe roof rail 18. In other words, the curvature of the bracket assembly20 matches the curvature of the roof rail 18. Since the curvature of thebracket assembly 20 matches the curvature of the roof rail 18, thebracket assembly 20 reduces the size and/or number of intrusion points,e.g., for water, debris, etc., into the roof frame 14. By reducing thesize or number of intrusion points, e.g., for water, debris, etc., intothe roof frame 14, the bracket assembly 20 may prevent or reducecorrosion of the pillar 22.

The vehicle 10 may, for example, be any suitable type of automobile. Thevehicle 10 may include two sides 34, 36 spaced from each other in across-vehicle direction Dc. The two sides 34, 36 of the vehicle 10 mayextend transverse to the cross-vehicle direction Dc. For example, thetwo sides 34, 36 may each be elongated in a vehicle fore-and-aftdirection Df. Each side of the vehicle 10 may be similar or identical toeach other. Common numerals are used to identify common features on eachside of the vehicle 10. The two sides 34, 36 of the vehicle 10 may bemirror images of each other about the vehicle fore-and-aft direction Df.

With reference to FIG. 1A, the vehicle 10 may include a vehicle body 38defining a passenger cabin 40 to house occupants, if any, of the vehicle10. The passenger cabin 40 includes front seats (not shown) disposed ata front (not numbered) of the passenger cabin 40 and rear seats (notshown) spaced from the front seats. The rear seats may be, for example,disposed behind the front seats in the passenger cabin 40, e.g., at arear (not numbered) of the passenger cabin 40. The passenger cabin 40may also include third-row seats (not shown) at the rear of thepassenger cabin 40, in which case the front seats may be second-rowseats (not numbered) instead of or in addition to being front seats. Thefront seats and the rear seats may be a same or different type of seat.The front seats and rear seats may be any suitable type of seats. Thefront seats and the rear seats may be, for example, a bucket seat.

With continued reference to FIG. 1A, the vehicle body 38 may include afront fender 42 and a rear fender 44 spaced from the front fender 42 inthe vehicle fore-and-aft direction Df. Specifically, the body mayinclude one front fender 42 and one rear fender 44 on each side of thevehicle 10. In other words, the body may include on front fender 42 andone rear fender 44 on one side 34 of the vehicle 10 and another frontfender 42 and another rear fender 44 on the other side 36 of the vehicle10. The front fenders 42 are spaced from each other in the cross-vehicledirection Dc, and the rear fenders 44 are spaced from each other in thecross-vehicle direction Dc.

With continued reference to FIG. 1A, the vehicle body 38 may include afloor 46 and the roof assembly 12 spaced from the floor 46. The roofassembly 12 may include the roof frame 14 and the at least one exteriorpanel 16 releasably connected to the roof frame 14, as set forth above.The floor 46 may include rockers (not numbered) extending along eachside of the vehicle 10. For example, the rockers may extend in thevehicle fore-and-aft direction Df. The rockers may be formed of anysuitable material, e.g., steel, boron, etc.

With continued reference to FIG. 1A, the roof frame 14 may extend in thevehicle fore-and-aft direction Df from the front fender 42 to the rearfender 44 of the vehicle 10. Additionally, the roof frame 14 may extendin the cross-vehicle direction Dc from one side 34 to the other side 36of the vehicle 10. In other words, the roof frame 14 may extend to eachof the fenders.

With continued reference to FIG. 2, the roof frame 14 may include roofrails 18 spaced from each other in the cross-vehicle direction Dc. Forexample, the roof frame 14 may include one roof rail 18 on one side 34of the vehicle 10 and another roof rail 18 on the other side 36 of thevehicle 10. The roof rail 18 may be elongated in the vehiclefore-and-aft direction Df. For example, the roof rail 18 may extend fromthe front fender 42 to the rear fender 44 of the vehicle 10. The roofrail 18 may be formed of any suitable material, e.g., mild steel.

With reference to FIG. 2, the roof rail 18 may include a top 48 spacedfrom the bottom 24 in a direction D transverse, e.g., perpendicular, tothe vehicle fore-and-aft direction Df and the cross-vehicle directionDc. The top 48 is above the bottom 24. The direction D, for example, maybe vertical. The top 48 may abut the exterior panel 16 when the exteriorpanel 16 is in the covered position. In other words, the top 48 isdisposed between the exterior panel 16 and the bottom 24 when theexterior panel 16 is in the covered position. The bottom 24 faces thefloor 46. In other words, the bottom 24 is disposed between the top 48and the floor 46 of the vehicle 10.

With reference to FIG. 3, the roof rail 18 may include an inner side 50and an outer side 52 spaced from the inner side 50 in the cross-vehicledirection Dc. The inner side 50 and the outer side 52 extend from thebottom 24 in a direction transverse, e.g., perpendicular, to thecross-vehicle direction Dc. The inner side 50 and the outer side 52 mayextend in the direction D from the bottom 24 to the top 48 of the roofrail 18. The roof rail 18, i.e., the bottom 24, the top 48, the innerside 50, and the outer side 52, may be rectangular, e.g., square, incross-section.

The inner side 50 may face the passenger cabin 40, and the outer side 52may face away from the passenger cabin 40, i.e., the exteriorenvironment. The roof rail 18 may include a transition Tr from thebottom 24 to each of the inner side 50 and the outer side 52, and fromthe top 48 to each of the inner side 50 and the outer side 52. Thetransition Tr may be rounded. In other words, the roof rail 18 may havea generally rounded shape, e.g., e.g., circular, elliptical, roundedrectangle, rounded square, rounded polygon, etc.

With reference to FIGS. 1A & 1B, the roof frame 14 may include anysuitable number of pillars 22 on each side of the vehicle 10. Thepillars 22 may be disposed between the front fender 42 and the rearfender 44 of the vehicle 10. The pillars 22 may be spaced from eachother in the vehicle fore-and-aft direction Df. The pillars 22 mayextend downwardly from the bottom 24 of the roof rail 18 towards thefloor 46.

With reference to FIG. 3, the pillar 22 is fixed to the roof rail 18 bythe bracket assembly 20. Specifically, the pillar 22 is fixed to thebracket assembly 20 and the bracket assembly 20 is fixed to the roofrail 18. The pillar 22 may be fixed to the bracket assembly 20 in a sameor different manner as the bracket assembly 20 is fixed to the roof rail18. For example, the pillar 22, bracket assembly 20, and roof rail 18may be welded together (e.g., metal inert gas (MIG) welding, tungsteninert gas (TIG) welding, or any other suitable welding manner), and/oradhered together, etc.

With reference to FIG. 4A, the bracket inner 26 may include sealingsurfaces 54 spaced from each other in the vehicle fore-and-aft directionDf. The sealing surfaces 54 may include a top surface 56 extending inthe cross-vehicle direction Dc and a front surface 58 extending in thedirection D. The top surfaces 56 and the front surface 58 may be spacedfrom each other. In this situation, the bracket inner 26 may include atransition surface 60 extending from the top surfaces 56 to the frontsurface 58. The transition surface 60 may extend transverse, e.g., at anon-right angle, to both the direction D and the cross-vehicle directionDc. Alternatively, the front surface 58 and the top surfaces 56 mayintersect each other. In other words, the front surface 58 may extenddownwardly from the top surfaces 56, and the top surfaces 56 may extendlaterally from the front surface 58.

The bracket inner 26 may include wings 62 extending from the topsurfaces 56 s, respectively, to ends 64 spaced from each other in thevehicle fore-and-aft direction Df, as shown in FIG. 4A. In other words,the wings 62 are spaced from each other in the vehicle fore-and-aftdirection Df. The wings 62 may extend from the top surfaces 56 away fromeach other. In other words, one wing 62 may extend toward the front ofthe passenger cabin 40 and the other wing 62 may extend toward the rearof the passenger cabin 40. The wings 62 may abut the bottom 24 of theroof rail 18, as shown in FIG. 2. Specifically, the wings 62 may befixed, e.g., welded and/or adhered, etc., to the bottom 24 of the roofrail 18. The bracket inner 26 may be formed of any suitable material,e.g., mild steel, boron, etc.

The bracket inner 26 may include a flange 66 extending in the directionD, as shown in FIG. 4A. The flange 66 may extend in the vehiclefore-and-aft direction Df from the end 64 of one wing 62 to the end 64of the other wing 62. The flange 66 may be disposed adjacent to theinner side 50 of the roof rail 18, as shown in FIG. 2. For example, theflange 66 may extend upwardly along the inner side 50 of the roof rail18. The flange 66 may extend any suitable amount along the inner side 50of the roof rail 18. The flange 66 may be fixed, e.g., welded and/oradhered, etc., to the inner side 50 of the roof rail 18.

The bracket inner 26 may include a transition Tf from the flange 66 toeach of the wings 62. The transition Tf may be rounded. Specifically,the transition Tf between the wings 62 and the flange 66 may match,i.e., have the same curvature as, the transition Tr between the bottom24 and the inner side 50 of the roof rail 18. In other words, thetransition Tf between the wings 62 and the flange 66 may abut thetransition Tr between the bottom 24 and the inner side 50 of the roofrail 18.

The bracket outer 28 may include a surface 68 extending in the vehiclefore-and-aft direction Df from one wing 62 to the other wing 62 of thebracket inner 26, as shown in FIG. 4B. The surface 68 may abut thebottom 24 of the roof rail 18. In other words, the surface 68 and thewings 62 may extend in a plane P along the bottom 24 of the roof rail18. As an example, the plane P may be horizontal. The surface 68 may beelongated in the vehicle fore-and-aft direction Df. A space between thesurface 68 and each of the wings 62 may be beneath the bottom 24 of theroof rail 18, e.g., in a vertical direction, to reduce the likelihood ofexposure to water and/or hide the space from sight. The bracket outer 28may be formed of any suitable material, e.g., mild steel, boron, etc.

The surface 68 may include an inner edge 70 and an outer edge 72 spacedfrom the inner edge 70 in the cross-vehicle direction Dc, as shown inFIG. 4A. The inner edge 70 of the surface 68 may be adjacent to theinner side 50 of the roof rail 18, and the outer edge 72 of the surface68 may be adjacent to the outer side 52 of the roof rail 18, as shown inFIG. 2. In other words, the surface 68 may extend in the cross-vehicledirection Dc from the inner side 50 to the outer side 52 of the roofrail 18, i.e., across the bottom 24 of the roof rail 18 in thecross-vehicle direction Dc. A space between the inner edge 70 and thebracket inner 26, e.g., the flange 66, may be beneath the bottom 24 ofthe roof rail 18, e.g., in a vertical direction, to reduce thelikelihood of exposure to water and/or hide the space from sight. Theinner edge 70 of the surface 68 may be disposed adjacent to the flange66 of the bracket inner 26. For example, the inner edge 70 of thesurface 68 may abut the flange 66 of the bracket inner 26. The surface68 is fixed, e.g., welded and/or adhered, etc., to the bottom 24 of theroof rail 18.

A sealant 74 may be sandwiched between the outer edge 72 of the surface68 and the bottom 24 of the roof rail 18, e.g., the transition Tr fromthe bottom 24 of the roof rail 18 to the outer side 52 of the roof rail18. The sealant 74 may prevent water and debris from entering betweenthe surface 68 and the bottom 24 of the roof rail 18 when the vehicle 10is in operation, e.g., when the exterior panel 16 is in the uncoveredposition. The sealant 74 may be disposed along the outer edge 72 of thesurface 68 from one wing 62 to the other wing 62, i.e., along the entirelength of the surface 68. The sealant 74 may be any suitable weldablematerial, e.g., acrylic, epoxy, polyurethane, rubber based butyl, etc.Alternatively, the sealant 74 may be any suitable structural adhesive,e.g., urethane, two-part epoxy, etc.

With reference to FIG. 4A, the bracket outer 28 may include an outersurface 76 elongated in the vehicle fore-and-aft direction Df andextending in the direction D. The outer surface 76 may include a bottomedge 78 spaced from the surface 68 in the direction D. The outer surface76 may include a top edge 80 spaced from the bottom edge 78 in thedirection D. The top edge 80 may be spaced from the surface 68. In thissituation, the bracket outer 28 may include an intermediate surface 82extending from the outer surface 76 to the surface 68. In thissituation, the intermediate surface 82 may extend transverse, e.g. at anon-right angle, to both the cross-vehicle direction Dc and thedirection D. Alternatively, the top edge 80 may abut the surface 68. Inthis situation the outer surface 76 may extend downwardly from thesurface 68 to the bottom edge 78.

With continued reference to FIG. 4A, each of the surface 68, theintermediate surface 82, and the outer surface 76 may face away from thepassenger cabin 40. The bracket outer 28 may include an inner surface 84extending along the bracket outer 28 from the inner edge 70 of thesurface 68 to the bottom edge 78 of the outer surface 76. The innersurface 84 may face the opposite direction as the surface 68, theintermediate surface 82, and the outer surface 76. In other words, theinner surface 84 may face toward the passenger cabin 40, i.e., thebracket inner 26. The inner surface 84 of the bracket outer 28 extendsalong the sealing surfaces 54 of the bracket inner 26, e.g., from thesurface 68 to the front surface. The inner surface 84 of the bracketouter 28 may be fixed to the sealing surfaces 54 of the bracket inner26, e.g., from the top surfaces 56 to the front surface.

With continued reference to FIG. 4A, the sealant 74 may be sandwichedbetween the bracket inner 26, and the bracket outer 28. For example, thesealant 74 may be sandwiched between the sealing surfaces 54 of thebracket inner 26 and the inner surface 84 of the bracket outer 28. Thesealant 74 may, for example, be disposed entirely along the sealingsurfaces 54, e.g., from the top surfaces 56 to the front surface.

The pillar inner 30 may be disposed between the pillar outer 32 and thepassenger cabin 40, as shown in FIG. 3. In other words, the pillar inner30 may face the passenger cabin 40. The pillar inner 30 may be elongatedin the direction D. The pillar inner 30 may, for example, extend fromthe floor 46 to the roof rail 18 of the vehicle 10. As another example,the pillar inner 30 may extend from the floor 46 to the bracket inner26, i.e., the pillar inner 30 may be spaced from the roof rail 18. Thepillar inner 30 may be formed of any suitable material, e.g., mildsteel, boron, etc.

With reference to FIG. 3, the pillar inner 30 includes walls 86 spacedfrom each other in the vehicle fore-and-aft direction Df and a back 88extending from one wall 86 to the other wall 86. The walls 86 and theback 88 define a channel 90 elongated in the direction D. The channel 90may be sized to receive the bracket inner 26. For example, the bracketinner 26 may be disposed in the channel 90 and abut the walls 86 and theback 88 of the pillar inner 30. In other words, the channel 90 may coverthe bracket inner 26. The bracket inner 26 may be fixed, e.g., weldedand/or adhered, etc., to the pillar inner 30 in the channel 90.

With continued reference to FIG. 3, the walls 86 may include weldflanges 92 extending away from each other in the vehicle fore-and-aftdirection Df. In other words, the weld flanges 92 may each extend awayfrom the channel 90. The weld flanges 92 may be elongated in thedirection D. For example, the weld flanges 92 may extend entirely alongthe pillar inner 30 in the direction D.

The pillar outer 32 may face away from the passenger cabin 40 of thevehicle 10. The pillar outer 32 may be elongated in the direction D, asshown in FIG. 3. The pillar outer 32 may, for example, extend from theroof rail 18 to the floor 46 of the vehicle 10. As another example, thepillar outer 32 may extend from the floor 46 to the bracket outer 28,i.e., the pillar outer 32 may be spaced from the roof rail 18. Thepillar outer 32 may extend across the bracket outer 28 in the vehiclefore-and-aft direction Df. In other words, the pillar outer 32 may coverthe bracket outer 28 in the vehicle fore-and-aft direction Df. Thepillar outer 32 may be formed of any suitable material, e.g., mildsteel, boron, etc.

With reference to FIG. 3, the pillar outer 32 may include mountingflanges 94 spaced from each other in the vehicle fore-and-aft directionDf. The mounting flanges 94 may abut the weld flanges 92 of the pillarinner 30. Specifically, the mounting flanges 94 may be fixed, e.g.,welded and/or adhered, etc., to the weld flanges 92 of the pillar inner30. The mounting flanges 94 may be elongated in the direction D. Forexample, the weld flanges 92 may extend entirely along the pillar outer32 in the direction D.

With continued reference to FIG. 3, the pillar outer 32 may include aninside surface 96 facing the passenger cabin 40, i.e., the bracket outer28. The inside surface 96 of the pillar outer 32 may abut the bracketouter 28, e.g., the intermediate surface 82 and/or the outer surface 76.The inside surface 96 of the pillar outer 32 may be fixed, e.g., weldedand/or adhered, etc., to the bracket outer 28, e.g., the intermediatesurface 82 and/or the outer surface 76.

The sealant 74 may be sandwiched between the pillar inner 30 and thepillar outer 32. For example, the sealant 74 may be sandwiched betweenthe weld flanges 92 of the pillar inner 30 and the mounting flanges 94of the pillar outer 32. The sealant 74 may, for example, be disposedentirely along the weld flanges 92 and mounting flanges 94, e.g., in thedirection D.

With reference to FIG. 3, the pillar 22 may include a body side panel 98encompassing the pillar outer 32. In other words, the body side panel 98may extend from one mounting flanges 94 to the other mounting flange.The body side panel 98 may, for example, cover the pillar outer 32 andthe bracket outer 28. In other words, the body side panel 98 may extendto the roof rail 18. The body side panel 98 may abut the mountingflanges 94 of the pillar outer 32. In other words, the mounting flanges94 of the pillar outer 32 may be sandwiched between the body side panel98 and the weld flanges 92 of the pillar inner 30. In this situation,the body side panel 98 may be fixed, e.g., welded and/or adhered, etc.,to the pillar outer 32, i.e., the mounting flanges 94, and the pillarinner 30, i.e., the weld flanges 92. Additionally, the body side panel98 may abut the intermediate surface 82 of the bracket outer 28. Thebody side panel 98 may be fixed, e.g., welded and/or adhered, etc., tothe intermediate surface 82 of the bracket outer 28.

The body side panel 98 may be elongated from the roof rail 18 toward thefloor 46 any suitable amount. For example, the body side panel 98 mayextend from the roof rail 18 to the floor 46 of the vehicle 10. In thissituation, the body side panel 98 may be formed of any suitablematerial, e.g., mild steel. As another example, the body side panel 98may extend from the roof rail 18 to a position spaced from the floor 46,e.g., the top of a vehicle door, as shown in FIG. 2. In this situation,the body side panel 98 may be an applique. In other words, the body sidepanel 98 may be formed of a different material than the pillar outer 32,e.g., plastic, nylon, etc.

With reference to FIG. 1B, the roof frame 14 may include a plurality ofcross members 100 extending from one roof rail 18 to the other roof rail18. The cross members 100 may, for example, extend from the pillar 22 onone side 34 of the vehicle 10 to the pillar 22 on the other side 36 ofthe vehicle 10. The cross members 100 may be spaced from each other inthe vehicle fore-and-aft direction Df. The roof frame 14 may include anysuitable number of cross members 100. The cross members 100 may be fixedto the roof rails 18 in any suitable manner, e.g., welded, adhered,and/or fasteners, etc.

With reference to FIG. 1A, in the covered position, the exterior panel16 is connected to the roof frame 14. In this situation, the exteriorpanel 16 may cover the roof frame 14, i.e., the passenger cabin 40. Inother words, the exterior panel 16 may extend along the roof frame 14from the front fender 42 to the rear fender 44 and may extend across theroof from one side 34 to the other side 36. The exterior panel 16 may bereleasably connected to any suitable component of the roof frame 14,e.g., the roof rails 18, the cross members 100, etc. The exterior panel16 may be releasably connected to the roof frame 14 in any suitablefashion, e.g., clamps, latches, screws, bolts, etc.

In the uncovered position, the exterior panel 16 is released from theroof frame 14, i.e., spaced from the roof frame 14. In this situation,the exterior panel 16 may, for example, be stored in the vehicle 10,e.g., a cargo compartment. Alternatively, the exterior panel 16 may bestored in a location separate from the vehicle 10. When the exteriorpanel 16 is in the uncovered position, the roof frame 14 is exposed tothe environment, e.g., sunlight, wind, water, debris, etc. In otherwords, the passenger cabin 40 is exposed to the environment, as shown inFIG. 1B.

The exterior panel 16 may be formed of any suitable type of material.For example, the exterior panel 16 may be formed of steel.Alternatively, the exterior panel 16 may be formed of aluminum,fiberglass, carbon fiber, or any other suitable type of material.

The exterior panel 16 may be a single continuous unit, e.g., a singlepiece. Alternatively, the exterior panel 16 may include a plurality ofsegments, i.e., two or more, releasably connected to each other. Thesegments may be releasably connected to each other in any suitablefashion, e.g., clamps, latches, screws, bolts, etc.

In general, as described in more detail below in an exemplary process,the roof frame 14 is assembled to prevent water and debris from enteringthe pillar 22 when the exterior panel 16 is in the uncovered position.The shape of the bracket outer 28 and the bracket inner 26 reduce weldlines visible from the exterior of the vehicle 10 and reduce the size ornumber of intrusions between the bracket assembly 20 and the roof rail18.

The process begins by welding the bracket outer 28 to the bottom 24 ofthe roof rail 18. Specifically, the surface 68 is welded to the bottom24 of the roof rail 18. When the bracket outer 28 is welded to thebottom 24 of the roof rail 18, sealant 74 may be disposed between theouter edge 72 of the surface 68 and the transition Tr between the outerside 52 and the bottom 24 of the roof rail 18.

Next, the sealant 74 is disposed along the sealing surfaces 54 of thebracket inner 26, as set forth above. The bracket inner 26 is positionedsuch that the bracket outer 28, i.e., the surface 68, extends from onewing 62 to the other wing 62. Additionally, the inner surface 84 of thebracket outer 28 is adjacent to the sealing surfaces 54 of the bracketinner 26. The sealant 74 is sandwiched between the inner surface 84 ofthe bracket outer 28 and the sealing surfaces 54 of the bracket inner26.

Next, the bracket inner 26 is welded to the bracket outer 28 and theroof rail 18. Specifically, the wings 62 of the bracket inner 26 arewelded to the bottom 24 of the roof rail 18, and the flange 66 of thebracket inner 26 is welded to the inner side 50 of the roof rail 18.Additionally, the sealing surfaces 54 of the bracket inner 26 are weldedto the inner surface 84 of the bracket inner 26.

Next, the pillar inner 30 is positioned around the bracket inner 26 suchthat the bracket inner 26 is disposed in the channel 90 of the pillarinner 30. The sealant 74 may be disposed in the channel 90 such that thesealant 74 is sandwiched between the channel 90 and the bracket inner26. The pillar inner 30, i.e., the channel 90, is welded to the bracketinner 26.

Next, the sealant 74 may be disposed along the weld flanges 92 of thepillar inner 30. The pillar outer 32 is positioned such that themounting flanges 94 abut the weld flanges 92. In other words, the pillarouter 32 extends across the bracket outer 28. For example, the insidesurface 96 of the pillar outer 32 abuts the intermediate surface 82 andthe outer surface 76 of the bracket outer 28. The pillar outer 32 iswelded to the bracket outer 28, i.e., the intermediate surface 82.

Next, the body side panel 98 is positioned such that the body side panel98 abuts the mounting flanges 94 and the bottom 24 of the roof rail 18.The sealant 74 may be disposed along the mounting flanges 94. In otherwords, the sealant 74 may be sandwiched between the body side panel 98and the mounting flanges 94. Additionally, the body side panel 98 abutsthe bracket outer 28, e.g., the intermediate surface 82, and the pillarouter 32.

Next, the body side panel 98 is welded to the intermediate surface 82 ofthe bracket outer 28. Additionally, the body side panel 98 is welded tothe pillar outer 32, i.e., the mounting flanges 94, and the pillar inner30, i.e., the weld flanges 92. In other words, the body side panel 98,the mounting flanges 94 of the pillar outer 32, and the weld flanges 92of the pillar inner 30 are welded together.

When the exterior panel 16 is in the covered position, the exteriorpanel 16 shields the roof frame 14 from the environment, e.g., water,debris, etc. When the exterior panel 16 is in the uncovered position,the roof frame 14 is exposed to the environment, e.g., water, debris,etc. The bracket assembly 20 is designed to match the contour, i.e.,curvature, of the roof rail 18 to prevent water intrusion into thepillar 22. Additionally, the design of the bracket assembly 20 reducesthe visible weld lines when an occupant views the vehicle 10 from theside outside the passenger cabin 40. In other words, the bracket isdesigned such that weld lines are disposed on the inner side 50 of theroof rail 18, i.e., facing the passenger cabin 40. By reducing waterintrusion into the pillar 22, the bracket assembly 20 assists inpreventing or reducing corrosion of the pillar 22 and other vehiclecomponents, e.g., the rockers.

The disclosure has been described in an illustrative manner, and it isto be understood that the terminology which has been used is intended tobe in the nature of words of description rather than of limitation. Manymodifications and variations of the present disclosure are possible inlight of the above teachings, and the disclosure may be practicedotherwise than as specifically described.

What is claimed is:
 1. A roof frame comprising: a roof rail including abottom; a bracket assembly including a bracket inner and a bracket outerfixed to each other, the bracket inner and the bracket outer fixed tothe bottom of the roof rail; and a pillar including a pillar inner fixedto the bracket inner and a pillar outer fixed to the bracket outer, thepillar inner and the pillar outer fixed to each other.
 2. The roof frameof claim 1, wherein the bracket outer includes a surface extending in avehicle fore-and-aft direction, the surface being fixed to the bottom ofthe roof rail.
 3. The roof frame of claim 1, wherein the roof railincludes an inner side and an outer side spaced from each other in across-vehicle direction, the inner side and the outer side extendingfrom the bottom in a direction transverse to the cross-vehicledirection.
 4. The roof frame of claim 3, wherein the bracket innerincludes a flange extending in the direction along the inner side of theroof rail, the flange being fixed to the inner side of the roof rail. 5.The roof frame of claim 1, wherein the bracket inner includes wingsspaced from each other in a vehicle fore-and-aft direction, the wingsbeing fixed to the bottom of the roof rail.
 6. The roof frame of claim5, wherein the bracket outer includes a surface extending in the vehiclefore-and-aft direction from one wing to the other wing, the surface andthe wings extend in a plane along the bottom of the roof rail.
 7. Theroof frame of claim 6, wherein the bracket inner includes a flangeelongated in the vehicle fore-and-aft direction, the surface includes aninner edge abutting the flange from one wing to the other wing.
 8. Theroof frame of claim 7, wherein the surface includes an outer edge spacedfrom the inner edge in a cross-vehicle direction, and further comprisinga seal sandwiched between the outer edge of the surface and the bottomof the roof rail, the seal extending from one wing to the other wing. 9.The roof frame of claim 1, wherein the bracket assembly includes a sealsandwiched between the bracket inner and the bracket outer.
 10. The roofframe of claim 9, wherein the bracket inner includes sealing surfacesspaced from each other in a vehicle fore-and-aft direction, each sealingsurface including a top surface extending in a cross-vehicle directionand a front surface extending in a direction transverse to thecross-vehicle direction.
 11. The roof frame of claim 10, wherein thebracket outer includes an inner surface abutting the sealing surfaces,the inner surface extending along each sealing surface from the topsurface to the front surface.
 12. The roof frame of claim 10, whereinthe seal is disposed along each sealing surface from the top surface tothe front surface.
 13. The roof frame of claim 12, wherein each sealingsurface includes a transition surface extending from the top surface tothe front surface, the seal disposed along the transition surface. 14.The roof frame of claim 1, wherein the pillar inner includes wallsspaced from each other in a vehicle fore-and-aft direction and a backextending from one wall to the other wall, the walls and the backdefining a channel and the bracket inner disposed in the channel. 15.The roof frame of claim 14, wherein the bracket inner abuts the wallsand the back of the pillar inner, the bracket inner being fixed to thepillar inner in the channel.
 16. The roof frame of claim 14, wherein thepillar inner includes a weld flange extending from each wall away fromthe channel in the vehicle fore-and-aft direction, and the pillar outerincludes mounting flanges spaced from each other in the vehiclefore-and-aft direction, the mounting flanges of the pillar outerabutting the weld flanges of the pillar inner, respectively.
 17. Theroof frame of claim 16, wherein a seal is sandwiched between themounting flanges of the pillar outer and the weld flanges of the pillarinner.
 18. The roof frame of claim 16, wherein the pillar includes abody side encompassing the pillar outer, the mounting flanges of thepillar outer being sandwiched between the body side and the weld flangesof the pillar inner.
 19. The roof frame of claim 1, wherein the pillarincludes a body side encompassing the pillar outer and the bracketouter, the body side fixed to the pillar outer and the bracket outer.20. The roof frame of claim 19, wherein the body side is fixed to thepillar inner.